Automotive lightweighting

Meeting the demands for more fuel efficient vehicles

Simulation for automotive lightweighting

Government regulations (CAFE) and consumer demand for vehicles with increased fuel economy are accelerating. With different options available to achieve fuel economy targets, automotive lightweighting is emerging as a clear favourite.

While physical prototyping and testing can be costly and time-consuming while returning limited results, Simulation allows you to fully explore different lightweighting opportunities within automotive designs

Automotive lightweighting simulation in action

Explore specific lightweighting examples by clicking the nodes on the vehicle and view the associated simulation results.

DATA ATTRIBUTES INFORMATION ARE HERE!! - NEEDS TO BE UPDATE FOR EACH CAR PARTS

Hood

OBJECTIVE

Predict / Validate

PROCESS

Using data from a draping simulation, as-manufactured material properties were extracted and analysed. Fibre orientations were determined and the structural integrity of the part was verified to determine that it met the functional specifications.

BENEFITS

Weight reduction

Strengthen

TYPE

100% carbon fibre

Fuel economy boost

Weight reduction

1.188%

-38 lbs / -17.2 kg

DATA ATTRIBUTES INFORMATION ARE HERE!! - NEEDS TO BE UPDATE FOR EACH CAR PARTS

Front fascia

OBJECTIVE

Optimise

PROCESS

Using flexible cloud solving, hundreds of different materials and design iteration scenarios were tested to obtain the combination which yielded the lowest piece-part-cost and weight without taxing local computing resources.

BENEFITS

Weight reduction

Durability

Manufacturability

TYPE

100% plastic polymer

Fuel economy boost

Weight reduction

.094%

-3 lbs / -1.4 kg

DATA ATTRIBUTES INFORMATION ARE HERE!! - NEEDS TO BE UPDATE FOR EACH CAR PARTS

Seat pans (2)

OBJECTIVE

Validate

PROCESS

The manufacturing process was simulated and a warpage analysis was performed to ensure the quality of the final part and to validate the overmoulding process before any tooling investments were made.

BENEFITS

Weight reduction

Meet safety requirements

TYPE

Overmolded composite blank

Fuel economy boost

Weight reduction

.406%

-13 lbs / -5.9 kg

DATA ATTRIBUTES INFORMATION ARE HERE!! - NEEDS TO BE UPDATE FOR EACH CAR PARTS

Oil pan

OBJECTIVE

Predict

PROCESS

Fibre orientations were simulated and manipulated to optimise the strength of the part. The as-manufactured material properties were extracted to complete structural, thermal and vibration analysis to ensure product performance.

BENEFITS

Weight reduction

Durability

Metal replacement

TYPE

Fibre-reinforced plastic

Fuel economy boost

Weight reduction

.188%

-6 lbs / -2.7 kg

DATA ATTRIBUTES INFORMATION ARE HERE!! - NEEDS TO BE UPDATE FOR EACH CAR PARTS

Valve Cover w/ Integrated Oil Separator

OBJECTIVE

Predict

PROCESS

Simulation was used during the design stage to make decisions based on the manufacturability, material and thermal analysis, resulting in multiple components being combined into a single, integrated plastic part.

BENEFITS

Reduced part catalogue

Reduced assembly & tooling costs

Reduced complexity

High level of integration

Weight reduction

TYPE

Assembly to a single plastic part

Fuel economy boost

Weight reduction

.125%

-4 lbs / -1.8 kg

Reset calculator

Hood

Front Fascia

Seat Pans

Oil Pan

Valve Cover

Estimated fuel economy boost & weight reduction

Boost

Total weight reduction

2.0%

-64 lbs.

-29 kg

Advanced materials

As vehicle designs and functional requirements become more advanced, so do the materials. New materials are being developed every day, with more than 100 different types and gradients of plastic used in the average vehicle. For added strength and stiffness, fibres are injected into plastic parts during the manufacturing process.

Composite materials offer significant reductions in mass without sacrificing function. Advanced materials can be grouped into four categories.

Advanced processes

Compression moulding

Overmoulding

Microcellular injection

Plastic resins

Short and long fibre materials

Continuous fibre composites

Controlling the orientation of reinforcing fibres during the manufacturing process affects the strength and resistance properties of the part. Capturing these “as-manufactured“ material properties is critical to performing accurate analysis.

Simulation

Advanced materials require simulation tools designed to address analysis requirements. These materials react differently to traditional materials, due to their construction. Autodesk offers products that can help you to address the simulation requirements for automotive lightweighting applications.

Optimise the manufacturing process

Reduce weight

Control part strength and stiffness

Predict performance in practice

Select the best material for your application

Discover issues early in the design process

Direct from the industry

Learn from executives at leading companies as they share insights about trends in automotive lightweighting, the benefits of using plastics and composite materials and the role of simulation.

Conduct a Business Process Assessment

Let our Autodesk team of experts help you to identify software tools that can accurately simulate as-manufactured material properties and advanced materials, such as composites, to achieve your lightweighting goals.

We'll help you to create specific plans to get more from the investment and tools you already have and identify gaps you need to fill to improve your design and manufacturing practices.